Professional Documents
Culture Documents
E N G I N E S
Iveco SpA
PowerTrain
Publication edited by
Marketing - Adv. & Promotion
Print L31022018 - 01/05
8000
S
ERIES
GB
Liability
The manufacturer's liability is dependent on the execution of the
"Checks and Maintenance" operations mentioned in this manual.
For this purpose, a record must be kept of the maintenance operations carried out, which, as far as extraordinary maintenance is concerned, must be performed by authorised workshops.
Thank you for preferring Iveco Motors and may we compliment you
on the choice you have made.
Before carrying out any work on the engine, read through the procedures set out in this manual carefully.
If you follow these instructions your engine will be guaranteed trouble-free operation and a long life.
Remember that, wherever you are, the Iveco Motors Service
Network will be at your side to offer you highest levels of skill and
professionalism.
Warning
The contents of this manual refer to the engine only; in particular, illustrations are approximate and some instructions are described in
a purely functional manner, to permit the operations to be carried
out on the engine.
The ways of executing the above instructions depend on the configuration of the controls and/or accessories of the machine on which
the engine is installed and reference is made to the machine manual.
The information contained in this manual is correct at the time of publication.
The Manufacturer reserves the right to make amendments without
prior notice at any time for reasons of a technical or commercial nature as well as to comply with legal requirements in different countries. It declines any liability for any errors or omissions.
Guarantee
In order to get the best performance from your engine and benefit
from the guarantee you must comply with the instructions contained
in this publication.
Failure to carry out these operations correctly or not at all may invalidate the guarantee.
Spare parts
It is essential to use only Original Iveco Motors Spare Parts if the engine is to be kept in its original sound condition.
The use of non-original spare parts will invalidate the guarantee and
release Iveco Motors from any long-term liability.
LIST OF CONTENTS
Page
General information ........................................................................ 1
Safety requirements ........................................................................ 3
Warning labels ................................................................................. 4
Maintenance operations .................................................................. 5
Engine identification data................................................................. 5
Industrial engines
Engine views.................................................................................... 6
Engine data ...................................................................................... 9
Before starting................................................................................. 9
Starting the engine......................................................................... 10
Stopping the engine ....................................................................... 11
Water pre-heating ......................................................................... 11
Precautions for normal engine operation...................................... 12
Running in...................................................................................... 13
Checks and maintenance............................................................... 14
Routine checks .............................................................................. 16
Routine maintenance..................................................................... 20
SAFETY REQUIREMENTS
Basic rules
The following recommendations are given so as to reduce the risk to
persons and property when an engine is in service or out of service.
Engines must not be used for applications other than those declared
by the manufacturer.
Incorrect handling, modifications and use of non-original parts may
affect safety.
When handling the engine, take care to use suitable equipment to be
applied to the points specially provided on the engine (see paragraph
"Handling engine").
This publication refers to the engine component; the machine on
which it is installed must meet the specific safety requirements.
WARNING LABELS
Warning labels are applied to the engine by the machines builder.
Their meanings are given below.
N. B. Labels which show an exclamation mark indicate that there is
a possibility of danger.
Danger of burns:
Expulsion of pressurised hot water.
Danger of burns:
Hot parts indication.
Fuel filler indication on tank
(where present).
Risk of fire:
Due to presence of fuel.
Lubricating oil filler indication.
MAINTENANCE OPERATIONS
For the purposes of safety it is important that the maintenance operations indicated in this manual are carried out according to the following guidelines:
- checks, can be carried out both by the workshop and the machine user;
- routine maintenance checks, marked by the spanner symbol (see diagram below), must be carried out by qualified persons
using the appropriate equipment and protections;
- non-routine maintenance operations, given their particular nature, must be carried out by authorised workshops which
are equipped with the appropriate tools and are in possession of the
proper technical information.
"Authorised workshops" are those workshops belonging to the Iveco
Motors service organisation and those belonging to the machine manufacturer's service organisation if authorised by lveco Motors.
The technical code and the serial number are stamped on a label positioned, depending on the model, on the flywheel housing or tappet
cover.
INDUSTRIAL ENGINES
1. Intake manifold (8045SRE10) - 2. Fuel filters - 3. Starter motor 4. Intake manifold - 5. Injection pump - 6. Thermostat housing - 7.
Oil filler - 8. Fuel pump
WARNING
It is absolutely forbidden, at risk of invalidating the guarantee and the liability of Iveco Motors, to change the
above characteristics, and in particular to change the adjustment of
the injection pump and, where fitted, the waste-gate valve.
BEFORE STARTING
Every day, before starting the engine:
- check the fluid levels (fuel, engine oil and coolant).
- check that the air intake cleaner is not clogged, checking that the
mechanical indicator on the cleaner is not showing "red.
If the cleaner is clogged, clean it following the instructions set out in
the paragraph "Routine Checks and Maintenance.
N.B. When an electric indicator is fitted (optional) a warning light on
the control panel will light up immediately; in this case the cleaner
must be cleaned straightaway.
8035
E00
8045
E00
8045
SE00
8045
SRE10
Distrib.
NA
Distrib.
NA
Distrib.
TC
Distrib.
TCA
44 (60)
2500
335
59 (80)
2500
415
79.5 (108)
2300
400
92 (125)
2300
400
Attention!
Before starting the engine, check that the environment in
which you are to work is suitable for the mixture of harmful exhaust gases. Also check that combustible fuel gases such as
hydrocarbons are not present in the ambient air.
1. Buzzer
2. Oil gauge
3. Water temperature gauge
4. Voltmeter
5. Rev counter/hourmeter
6. Engine stop button
7. Starter/stop switch
8. Alarm indicators
10
If the engines are fitted with Iveco Motors instrument panels (optional), the engine is stopped by pressing the stop button (6) or by turning the starter key to "A".
If the engines are not fitted with an Iveco Motors instrument panel,
the starting instructions given previously may vary according to the
type of control panel fitted to the machine on which the engine is installed (see the instructions supplied by the machine's manufacturer).
WATER PRE-HEATING
(electric 220 V, single-phase - optional)
This device, supplied on request, is provided to aid starting at low
temperatures or in circumstances where an immediate supply of
power is required. It incorporates a thermostat which cuts off the
supply when the set temperature is reached.
WARNING!
Always check that the equipment is properly earthed.
11
oil in the lubrication system, follow the instructions given in the paragraph "Checks and maintenance".
Fuel system - Avoid working with the fuel tank at minimum reserve levels so as to prevent the formation of condensation and failure of the system due to intake of air, which causes the engine to
stop
Attention!
Intake and exhaust system - Check regularly that the air in-
Attention!
Never open the water filler plug when the engine is hot.
The cooling system is pressurised and the hot liquid will
be expelled violently if the pressure is released too violently, causing
burns.
Attention!
Visually inspect that the exhaust system is not blocked or
damaged so as to prevent dangerous fumes.
Lubrication system - Check that the oil pressure, with the engine hot and operating at normal speed, falls within the limits indicated in the table "Main regulation and repair data". If the oil pressure
does not correspond to the values indicated check the cause for this
by consulting the table "Engine fault diagnosis". When topping up the
12
Attention!
Do not smoke or bring naked flames in the vicinity of the
batteries to avoid explosions.
13
INTRODUCTION
The checks indicated in this section can be carried out either by
the workshop or by the machine user.
The routine maintenance operations, identified by the key
symbol, must be carried out by qualified personnel who have the appropriate equipment and protections.
The non-routine maintenance operations identified by
the spanner symbol, given their particular nature, must be carried
out by authorised workshops equipped with appropriate equipment
and with the proper technical information.
Attention!
Avoid carrying out maintenance when there is live voltage;
always check that the equipment is properly earthed.
During regulation operations make sure that you have dry hands
and feet and use insulating platforms.
DURING MAINTENANCE
- Never carry out repairs with which you are unfamiliar. Always follow the instructions and, if these are not available, contact the supplier or qualified personnel as described above.
- Always keep the engine clean, eliminating oil, diesel and/or coolant
stains.
- Place dirty rags inside flameproof containers.
- Do not leave rags on the engine.
- Use suitable secure containers for used oil.
- When you start an engine after a repair, take steps to stop the intake of air in case of over-rewing on starting.
14
CHECKS
NON-ROUTINE MAINTENANCE
Regularity
During its life the engine will also require certain specialist operations to be carried out, such as: valve seat dressing, turbocharger and
heat exchanger cleaning, injection pump, water pump and electrical
system overhaul.
Consult the Iveco Motors Service Network which is available to give
you advice and carry out the above operations promptly using fully
trained and professional personnel to ensure that the engine has a
long and efficient life.
Replace crankshaft damper (1):
- Engine 8045SE/SRE10 ____________________10,000 hours (6)
ROUTINE MAINTENANCE
Regularity
15
ROUTINE CHECKS
ENGINE OIL LEVEL CHECK
Carry out the check with the engine off, cold and with the machine
on the level.
Check that the oil level falls between the "Min" and "Max" limits
etched on the dipstick. If necessary, top up through the oil filler, after
turning the cap anti-clockwise.
WARNING
The level must never exceed the "Max" mark etched on
the dipstick. After the check, reposition the dipstick correctly and fully tighten the filler cap, turning it clockwise as far as it
will go. It is a must that the oil level be maintained between the
Min. and the Max. during the operation, especially during long operations.
16
To top up, use a mix of clean water and anti-freeze/corrosion inhibitor of the type described in the "Capacities" table.
During the winter months, check that there is the correct percentage of anti-freeze to prevent the engine being damaged by ice.
Different water level check procedures may be required depending
on the various cooling system configurations of the machine on which the engine is installed.
Attention!
Never open the water filler cap when the engine is hot.
The cooling system is pressurised and the hot fluid will
spurt out if the pressure is released too quickly, causing burns.
WARNING
If the cartridge is not properly fitted, unfiltered air could
enter the engine and cause serious damage. Where possible, have the above operations carried out by qualified personnel.
After the work on the cartridge has been completed, the mechanical
clogging indicator (see figure opposite) must be put back into service by pressing the special button located at the top of the indicator.
The electrical indicator does not require this operation.
18
Attention!
The batteries contain highly corrosive sulphuric acid;
when topping up with distilled water wear protective gloves and goggles. Where possible, have the above operations carried
out by qualified personnel.
Do not smoke or bring naked flames within the vicinity of the batteries to avoid explosions.
19
ROUTINE MAINTENANCE
Remember to have these operations carried out by specialist/authorised workshops, keeping to the specified intervals and bearing in
mind that the intervals may change depending on engine use and the
ambient conditions in which it operates.
20
1. Water radiator - 2. Water feed cap - 3. Exhaust manifold - 4. Alternator - 5. Engine lift eye - 6. Oil filter - 7. Oil drain plug.
21
1. Air filter - 2. Fuel filters - 3. Intake manifold - 4. Injection pump 5. Fuel pump - 6. Starter motor.
1. Water radiator - 2. Water feed cap - 3. Exhaust manifold - 4. Alternator - 5. Engine lift eye - 6. Oil filter - 7. Oil drain plug - 8. Oil
dipstick.
22
WARNING
It is absolutely forbidden, at risk of invalidating the guarantee and liability of Iveco Motors, to change the above
characteristics, and in particular to change the adjustment of the
injection pump.
GENERAL
The generating unit engine is derived from the industrial engine, the
difference being its fixed speed operation (1500 or 1800 rpm).
For this purpose the injection pumps are fitted with a special speed
governor mechanical type.
The mechanical governor normally provides (ISO 3046/IV class A1)
for a 5% speed deviation between no-load and full-load.
Set out below are all the operating and maintenance instructions for
generating unit engines that diverge from the instructions for industrial engine versions.
8031
i06
8041
i06
Distributor
Distributor
- Speed governor
mechanical
electronic
NA
NA
- Intake
- Net flywheel output: maximum standby power (fuel stop power) - ISO3046
1500 rpm
32 KW (43 CV)
41 KW (56 CV)
1800 rpm
36 KW (49 CV)
48 KW (65 CV)
370 Kg
415 Kg
- Dry weight
23
1. Before stopping the engine, allow it to run for a few minutes, with
no load; this allows a uniform reduction in the water and oil temperature, avoiding serious damage to the engine caused by thermal
shock.
2. The engine is stopped as described below:
De-energise the fuel shut-off solenoid valve by switching off the
power to the solenoid valve (the control system depends on the
configuration of the control panel).
Attention!
If the engine is part of a generating unit with automatic
start, starting can take place at any time. Therefore, for
the purposes of safety, refer to the recommendations indicated on
the manufacturer's documentation for the generating unit or the
complete system.
24
25
ENGINE VIEWS
Description
8031
i40
8041
i40
Injection pump
distributor-type
distributor-type
Governor
mechanical
mechanical
Aspiration
NA
NA
Net power at flywheel according to ISO 3046/1
2940 rpm
48 kW (65 CV)
64 kW (87 CV)
WARNING
Any alteration of the engine specifications listed above, and
in particular, the injection pump setting, is strictly prohibited. Any such alteration will invalidate the warranty and release
Iveco Motors from all liability.
26
GENERAL INFORMATION
STARTING
The fire pump engine is derived from an engine for industrial applications, from which it differs as regards power output and calibration
speeds.
Below are listed all the specific use and maintenance indications for
the fire pump engine that differ from those for the industrial version
of the engine.
BEFORE STARTING
Before periodic testing (weekly or in accordance with the intervals
specified in the regulation governing the fire-fighting system), carry
out the checks indicated in the section Before starting engines for
industrial applications .
IMPORTANT
To ensure easy starting, the fuel system must be free of
trapped air and full of fuel.
We also recommend that the fuel tank is always kept full in order to
ensure maximum economy and to reduce condensation.
WARNING
For engines equipped with the turbocharger protection device (Turbosafe), for the first start-up only (new engine),
start the engine and run without load at speed of ~ 1000 rpm for
approximately 5 minutes without switching it off.
This procedure serves to fill the reservoir of the turbocharger protection device with lubricating oil.
This procedure need not to be repeated at subsequent start-ups.
WARNING
If the engine is used in a fire-fighting system with an automatic start-up function, the engine may have to be started
at any time, and therefore, for reasons of safety, we advise you to
consult the documentation supplied by the system manufacturer of
the system.
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28
The table overleaf describes only those operations that the user and
the qualified personnel are authorised to perform to eliminate faults.
All other circumstances should be referred to an authorised
workshop equipped with the appropriate equipment and in possession of adequate technical information.
The diagnosis of the faults described below refers to the general causes which are valid for the majority of the applications; faults caused
by specific configurations of the machine or installation on which the
engine is installed cannot be envisaged.
Engine faults can be remedied, depending on their type by:
- user
- qualified personnel
- authorised workshop.
29
Fault
Possible cause
Possible cause
Fault
User:fill up
Qualified
personnel:
change the fuel filter; then
use a fuel suitable for winter use.
30
authorised
Other
Consult an authorised
workshop.
Radiator/cooler clogged
Fault
Possible cause
Fault
Defective injectors
Refer
to
workshop
Possible cause
authorised
31
Refer to
workshop
authorised
Refer to
workshop
authorised
7. Run the engine for 15 minutes at 500- 800 rpm; at the end, using
a syringe, slowly nebulise (in about 1 minute) the following quantity
of Prot. 30/M oil in the intake manifold:
1. Drain the oil from the sump and refill with flushing oil (e.g. FIAT
L20 oil). This operation applies only for engines which have already
operated for more than 200 hours.
9. Detach the injection system fuel line from the tank containing the
CFB oil and reconnect it to the fuel tank.
2. Run the engine for 15 minutes at 500-800 rpm; stop the engine
and drain the oil. This operation applies only for those engines which
have already operated for more than 200 hours.
10.Seal with adhesive tape all the access, vent and bleed openings on
the engine and exhaust pipe.
11. Affix a clearly visible label to the engine indicating that the unit is
"WITHOUT ENGINE OIL".
4. Pour into the engine sump FIAT Prot. 30/M oil up to the "Min" level indicated on the dipstick. If Prot. 30/M oil is not available use a
brand oil which meets requirements MIL-2160B - type 2.
6. After loosening the fuel filters, disconnect the injection system line
up-stream the fuel pump, and connect it to a special tank containing
CFB oil (ISO 4113).
32
Tightening torques
Cylinder head:
- 1st phase (pre-torque)........................................70 Nm (7.1 kgm)
- 2nd phase (pre-torque check) ............................70 Nm (7.1 kgm)
- 3rd phase (angle) ...................................................................... 90
- 4th phase (angle)....................................................................... 90
Connecting rod caps ................................... 40 Nm (4.1 kgm) + 60
Main bearing caps........................................ 80 Nm (8.2 kgm) + 90
Pulley-damper hub nut..........................................294 Nm (30 kgm)
Flywheel screws .......................................... 40 Nm (4.1 kgm) + 60
33
CAPACITIES
Parts
Quantity
Product
kg
~5
~6.7
7.7
11.5
10.5
7
10.5
9.5
4.4
7.2
6.4
4
6.5
5.8
6.6
10.5
9
6
9.5
8.2
Fuel tank
Mixture of water
and 50% Paraflu 11 (1)
WARNING
If fuel with a sulphur content of more than 0.5% or oil
type ACEA E2/API CF4/MILL 2104E/F is used in turbocharged engines, the engine oil change must be reduced to every 200 hours.
34
35
DISPOSAL
Please note that the engine and its components contain material necessary for its operation which, if dispersed in the environment, may
cause ecological damage.
The following materials must be consigned to special authorised collection centres:
- starter batteries
- used lubricating oils
- mixtures of water and anti-freeze
- filters
- auxiliary cleaning material (e.g. dirty or fuel-sodden rags)
Severe penalties are envisaged for transgressors, in accordance with
the laws in force in every country.
It is not permitted to lift the engine before removing the transmission components connected to it or other machine components supported by the engine.
The capacity and size of the engine lifting system must be adequate
for the weight and size of the engine; in particular, check that there
is no fouling between the lift system and the engine components.
It is important to use a lift balance to hold the metal lift cables parallel.
36
WHAT TO DO IN AN EMERGENCY
Any user of the machine, constructed according to safety regulations, who follows the instructions set out in this manual and complies with the instructions on the labels affixed to the engine is
working in safe conditions.
If operating mistakes cause accidents call for help immediately from
the emergency services.
In the event of an emergency, and whilst awaiting the arrival of the
emergency services, the following general advice is given for the provision of first aid.
Put out the fire using extinguishers recommended by the manufacturer of the machine or the installation..
Burns
Caustic burns
Fire
1) Caustic burns to the skin are caused by acid escaping from the batteries:
- remove the clothes
- wash with running water, being careful not to affect injury-free
areas
2)Caustic burns to the eyes are caused by battery acid, lubricating oil
and diesel fuel.
- wash the eye with water for at least 20 minutes, keeping the eyelids open so that the water runs over the eyeball and moving the eye
in all directions.
1)Put out the flames on the clothing of the burns victim by means of:
- drenching with water
- use of powder extinguisher, making sure not to direct the jets
onto the face
- blankets or rolling the victim on the ground.
2)Do not pull off strips of clothing which are sticking to the skin
3)In the case of scalding with liquids, remove the soaked clothing
quickly but carefully;
4)cover the burn with a special anti-burn packet or with a sterile
bandage.
37
Electrocution
Electrocution can be caused by:
1) the engine's electrical system (12/24 V)
2) the electrical generator system (generating units)
In the first case, the low voltage does not involve high current flows
through the human body; however, if there is a short circuit, caused
by a metal tool, sparks and burns may occur.
In the second case, the high voltage causes strong currents which can
be extremely dangerous.
If this happens, break the current by operating the switch before
touching the injured person.
If this is not possible, bear in mind that any other attempt is highly
dangerous also for the person assisting; therefore, any attempt to
help the victim must be carried out without fail using means which
are insulating.
38